Self Build Demountable

Having looked at whats on offer second hand (not a lot!!!) and the truley mental prices of buying new here in the UK, then comparing costs of buying in the USA (very bad £-$ exchange rates and extortionate shipping charges!!) ive decided to seriously look into building my own demountable truck camper.

Anyone on here over had a go and if so any tips or suggestions??

Not looking to build a palace just a reasonable size for 2 adults and maybe a child stuffed in a corner!!, weight is a huge factor as my pickup only has single wheels at the back and a 6 ft bed.

Looking at building the frame from aluminium and transplanting the windows/door, interior etc from a caravan.

Biggest problem seem to be finding the cladding to go on the outside (either aluminium or fibreglass) so any suggestions much appreciated.

Hi Dazzer,there is a supplier around here but I don't know his number,but have a contact who does :thumb: unfortunately he's away for 3 weeks give me a reminder shout if needed :thumb:
My ambulance is made up of ali bonded to 4 / 5 mm ply 45 mm Styrofoam then ali but you could get away without the internal ali because I used 3 mm furniture boards inside as well
The ali sheeting cost about £80 for a 10 ft x 5 ft sheet but 8 ft x 4 ft were under £50 each 1.5 mm thick. Normal thickness for a m/h is .5 mm
You can get caraseal from O'Leary for £4 a tube which will stick the boards to ali no problem,they also supply internal 3 mm boards at aprox £15 for a 7 ft x 4 ft ask for a discount :thumb:You can also buy everything you will need from o'learys but if you want I can also put you in touch with a supplier who has a truma boiler for £220 windows at about 150 and large remis roofs £200 also some leccy single steps at 200.Anythin else just ask :thumb:
terry

Having looked at whats on offer second hand (not a lot!!!) and the truley mental prices of buying new here in the UK, then comparing costs of buying in the USA (very bad £-$ exchange rates and extortionate shipping charges!!) ive decided to seriously look into building my own demountable truck camper.

Anyone on here over had a go and if so any tips or suggestions??

Not looking to build a palace just a reasonable size for 2 adults and maybe a child stuffed in a corner!!, weight is a huge factor as my pickup only has single wheels at the back and a 6 ft bed.

Looking at building the frame from aluminium and transplanting the windows/door, interior etc from a caravan.

Biggest problem seem to be finding the cladding to go on the outside (either aluminium or fibreglass) so any suggestions much appreciated.

Any helpful tips or pitfalls to avoid also much appreciated :thumb:

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you could use a bt demountable box and alter the sides about lot of work granted
have a look in member builds on sbmcc

While you are cruising in your hot truck!:thumb:
take a look at the way 7 1/2 ton. truck bodies are made, some have alli sheet fixed to alli frame ( you would fill with an insulation like "celotex") others use alli or a fiberglass sheet (I think the Yanks call it "filon") bonded to a light board, both of these are worth looking at.
FWIW I would not even consider adapting a box to do the job, I believe the over-cab section must be part of the whole side frame to get the strength without putting on weight.
If you can find a modern pranged caravan, you could gather a lot of expensive bits in one go. I would suggest that you had a plan of what you would like included, then gather all the bits before you cut your first bit of material. (you can't plan in the windows etc. until you know their size.
Nigel & Pamala

A caravan would be the first purchase, i recon i would get about 80% of the internal fittings/windows/door and other bits of kit on a reasonably modern crash damaged van. Would also use the electrical stuff and shower etc. :thumb:

I couldnt really start to design it till i had the doors and windows and a good idea of internal layout which will be dictated by the donar caravan. oh:

I am waiting on prices for cladding/internal walls and aluminium box section.

I wouldnt go down the route of adapting a box van, too much work in undoing before redoing and the layout would be compromised.

The demount is to be used as accomodation when we go diving in some pretty remote locations so it would need to be totally self contained and if i can find space and weight i would fit a small petrol powered H/P compressor. :thumb:

My main problem seems to be finding the jack legs. The only place i can find any for sale is the USA and they are electrically operated which i dont want because of the weight, they are also bloody expensive!!!.........any ideas anyone??

Test for braking ........it dont have brakes........or wheels for that matter

Strength tests.....no idea but as im building it myself i can guarantee it will be stronger than anything you can buy "off the shelf" and considerably better made :thumb:

The only testing that will be happening will be a leccy and gas/carbon monoxide test for the gas appliances.

Im sure there are some Euro rules and regulations but i wont be getting involved with any of that, i know it will be more than strong enough (i always over-engineer anything i make :thumb and the thing will be well secured to the pick up (after all i dont want to scratch my baby )

As for a 5er....I wish but wifee wont hear of it and to be honest some of the places we dive are a little "off the beaten track" and access would be a nightmare. I take the Lightning whenever i go diving and know that we can always get to waters edge in it so a demount seems to be the obvious choice.

Hi Dazzer,well you had me thinking a 5th wheeler / artic type
ACROW props :thumb::thumb::thumb:buy your caravan and see what you can salvage body work wise as well as the internals:thumb:
terry

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Acrow props are not a lot of use as they only jack up and down a small amount. The jacks fitted to demounts lift the body off the pick up and then drop it down to just above floor level for easy access. I recon the jacks need to raise and lower a couple of feet which is way beyond Acrows use. There is also the matter of the weight of 4 Acrows

hi dazzler !.... i may have the doner trailer you want. i have an american pop-up trailer that a kind belguim drunk kindley wrecked by ramming me last year !.... i was going to strip it down a make a camper out of my van.. but now i think 5th wheel is the way to go !the internals are all good ... shower, hot and cold water !. heating unit, water tank 27ltr, and a folding cooker!!.. slide out beds both ends!!... it cranks up on a 4 post system, maybe you could engineer this to suit your jacking leg problems???

Have you looked at a SMALL US 5er?? it would probably be cheaper than building a TC from scratch, I realise the reasons against it but a SMALL one would give you more comfort, and it would follow really well!!!!!
I believe that your bed is quite short?? a truck camper to suit would be quite minimal, the upside of that is that it would be nice and light!! A "pop-top" would allow you to travel rather quickly !! but would be a nightmare to build yourself!!
Can you mount the compressor to the truck's chassis??
We will get you totally confused yet!!!
Nigel & Pamala

If i go to the trouble of a small 5er i may as well buy a UK caravan :Blush:

Some of the places we dive are simply too tight for even the smallest 5er.

A pop top you say I think not :Blush:

Going quickly in the Lightning is not a problem :thumb::Blush: you could load it up with 3 tonnes of bricks and not notice

The bed is 6 feet long (a LOT bigger then the Jap Crap trucks but still a bit weedy by USA standards). Im not looking to build a palace just a place to kip/cook/shower in the arsehole of nowhere and still give us the flexibility of the truck for dragging tanks/heavy diving gear around once we arrive.

Bolt a compressor to my baby are you mad!!!!!

Its going to break my heart taking off the hard top to fit the demount

hi dazzler !.... i may have the doner trailer you want. i have an american pop-up trailer that a kind belguim drunk kindley wrecked by ramming me last year !.... i was going to strip it down a make a camper out of my van.. but now i think 5th wheel is the way to go !the internals are all good ... shower, hot and cold water !. heating unit, water tank 27ltr, and a folding cooker!!.. slide out beds both ends!!... it cranks up on a 4 post system, maybe you could engineer this to suit your jacking leg problems???

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Thanks for that but i think you are talking about the lift for the roof???? It wont be strong enough to lift the whole camper off the back of the truck but if you can email me some pics ill look at anything that might do the job :thumb: or give me inspiration